Cable Harness Assembly Stations With Integrated Radio Test Sensors
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Solution Overview
Problem
Current cable harness production systems face challenges with complex manual processes leading to high error rates and require extensive reconfiguration for small quantities or variants, necessitating a more efficient and automated testing solution that reduces the need for additional auxiliary wiring.
Innovation Solution
A cable harness production system with integrated test sensors that transmit results to a central controller via radio signals, eliminating the need for additional auxiliary wiring, and utilizing energy generated mechanically or through solar modules, allowing for quick assembly and adaptation of assembly stations without extensive reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly processes are used for cable harness production, then flexibility in handling small quantities and variants is maintained, but error rates increase and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated testing systems equipped with test sensors that automatically detect assembly errors. The controller coordinates test message transmission and evaluation, substituting human inspection with automated electronic detection, thereby reducing error rates while maintaining flexibility for small batches and variants.
2Reliability
If automated robot systems are implemented for cable harness production, then error rates decrease and productivity increases, but investment costs and system complexity increase
Solution Approach 1:
The patent segments the production system into modular assembly stations, each equipped with its own test sensor and controller interface. This modular approach allows automated testing functionality to be distributed across multiple independent units rather than requiring a single complex centralized robot system, thereby reducing overall system complexity while maintaining automated error detection capabilities.
3Measurement precision
If auxiliary cables are used to connect test devices to cable harness ends, then testing capability is achieved, but reconfiguration time increases and device complexity increases
Solution Approach 1:
The patent extracts the testing functionality from the cable harness itself by equipping assembly stations with integrated test sensors that directly detect assembly correctness at each station. This eliminates the need for auxiliary test cables that would otherwise need to be connected to cable harness ends, allowing rapid reconfiguration when production requirements change without time-consuming cable reconnections.
4Adaptability or versatility
If assembly stations are frequently reconfigured for different cable harness variants, then adaptability is maintained, but assembly time and conversion efforts increase
Solution Approach 1:
The patent implements dynamic reconfigurability in assembly stations through controllers that can be programmatically adjusted for different cable harness variants. Rather than requiring physical reconfiguration of mechanical components for each variant, the system dynamically adapts by loading appropriate test parameters and sensor configurations, thereby maintaining high adaptability while minimizing assembly time and conversion efforts.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This system reduces production errors and simplifies the adaptation of assembly stations, enabling efficient testing and production of cable harnesses with reduced planning and conversion efforts, suitable for various cable types and flexible hoses or pipes.
Implementation Method 1
which is able to send a test message as an electrical wave and receive and evaluate it
Implementation Method 2
The energy required for this is generated at the assembly station either via an electrical generator or with the help of solar modules
Data Source
Figure 1
AI summary
Disclosed is a cable harness production system comprising an electronic controller and at least one installation board to which several mounting stations are fastened. Each of said mounting stations supports a receptacle for a functional element, which is directly connected to at least one cable of the cable harness, or is shaped as a cable installation aid, e.g. as a fork. At least one electronic transmitter encompassing a test sensor is integrated into at least one mounting station. Said electronic transmitter can be activated by mounting a functional element or installing a cable in the cable installation aid. A test message can be transmitted as an electric wave and can be received and evaluated by the controller.